Copper-zinc oxide (Cu/ZnO) catalyst powders were impregnated into paper-structured composites (catalyst paper) using a papermaking process. The paper-structured catalyst was subjected to the methanol steam reforming (MSR) process and exhibited excellent performance compared with those achieved by pellet-type or powdered catalyst. The catalyst paper demonstrated a relatively stable gas flow as compared to catalyst pellets. Furthermore, the MSR process was simulated by computational fluid dynamic (CFD) analysis, and the heat conductivity influence of the catalyst layer was investigated. Higher heat conductivity contributed to both higher methanol conversion and lower carbon monoxide concentration; localization of heat and chemical species such as hydrogen and carbon dioxide were improved, resulting in suppression of reverse water-gas shift reaction. The CFD analysis was applied to the design of a catalyst layer in which a suitable shape was suggested, where carbon monoxide formation was further suppressed without a decrease in the methanol conversion. (c) 2008 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights reserved.